Expanded metal product



Dec. 27, 1938. w E MACK 2,141,400`

EXPANDED METAL PRODUCT Filed Jan. 11, 193e 2 sheets-sheet 2 .Y l INVENTOR Patented Dec. 27, 1938 UNITED STATES EXPANDED METAL PRODUCT Wayne E. Mack, Martins Ferry, Ohio, assignor to The Consolidated Expanded Metal Companies, geding, W. Va., a corporation of West Vir- Application January 11, 1936, Serial No. 58,719

11 Claims.

This invention' relates broadly to expanded metal products, and more particularly to. articles fabricated from expanded metal. It relates still more particularly to articles fabricated out of expanded metal and having a rim portion of the expanded metal itself.

Expanded metal is formed by slitting and expanding a metal sheet or plate. It comprises strands and bonds, the strands extending generally diagonally of the expanded metal sheet and transversely of one another and the bonds being relatively heavy portions at the junctions ,of the strands. A characteristic of expanded metal which has heretofore made it comparatively unsuitable for various uses is that the edges of the sheet are uneven. This is true not only in the original sheet as fabricated but also in any sheet which maybe cut therefrom and having edges substantially parallel with the edges of the original sheet. The end edges are especially sharp and jagged and the side edges are wavy.

vThis unevenness of the edges of expanded metal renders it unsuitable for many uses for which it would otherwise be ideal. Expanded metal is structurally strong and comparatively light yin` weight, and, were it not for the uneven edges, it could be put to'numerous uses for which it has heretofore been considered inadaptable. The uneven edges not only present a serious problem in fabrication but also render the expanded metal diflicult tohandle. v f

For example, expanded metal is, except for its edge characteristics, ideally suited for use as` shelving. This is particularly true of flattened expanded metal whose strands and bonds are compressed substantially into 'a common plane so that the opposed faces of the expanded metal are comparatively smooth. However, it has heretofore been considered necessary in adapting ex-f As a practical matter the application of a.l

frame to expanded metal used for shelving and similar purposes is in most cases undesirable for two reasons. In the first place, the frame un- (Cl. 'l2-117) desirably increases the weight ofthe shelf. In the second place, the cost incident to supplying, forming and attaching the frame is a major factor in the total expense of the product and greatly increases its cost.

I provide expanded metal products having rims of the expanded metal itself and integral therewith. Such provision renders expanded metal suitable for many purposes for which it' has heretofore been considered unsuitable. Moreover, such provision is of advantage in the manufacture of shelving. Shelves manufactured in accordance with my invention are even easier to handle than the framed shelves above referred to while at the Sametime the undesirable increase in both weight and cost brought about vby the provision, formation and attachment of frames is done away with. Still further, products made in accordance with my invention have a desirable stiffness or rigidity imparted by the deformation of the expanded metal itself.

' I preferably provide at an uneven edge of an expanded metal product a thickened marginal portion constituting a rim of the expanded metal itself and integral therewith. Such rim is preferably formed by turning the edge of the expanded metal, and I prefer to form a hollowrim by reverseiy turning such edge against and in contact with a face 'of the expanded metal. The rim thus formed provides a most convenient handle, and it is a fact that products made in accordance with my invention are far easier to handle than the framed shelving heretofore provided. The rim is preferably made of such size that it can be readily grasped with the hand,

or hide the undesirable uneven edges which are characteristic of expanded metal.

My invention may assume a wide variety of forms and is adapted for many diverse uses. Other details, objects and advantages of the invention will become apparent as the following description of certain present preferred embodiments thereof and certain present preferred methods of forming products in accordance therewith proceeds.

In the accompanying drawings I have shown certain present preferredembodiments of the invention and have illustrated diagrammatically certain present preferred methods of forming products in accordance therewith, in which Figure 1 is a plan View of a tray formed of expanded metal with portions cut away;

Figure 2 is a vertical longitudinal cross-sectional viewtaken on the line II-II of Figure 1;

35 the effect being at the same time to dispose of of structure; i

Figure 7 is an elevational view with portions out away of a gate member formed of -expanded metal;

Figure 8 is a horizontal longitudinal crosssectional view taken on the line VIII--VIII of Figure 7;

Figures 9, 10 and 11 are diagrammatic views showing one method of forming an expanded metal product having an integral rim of the expanded metal itself; and

-Figures 12, 13 and 14 are diagrammatic views showing another method of forming a similar product.

Referring now more particularly to the drawings, there is shown in Figure 1 a tray designated generally by reference numeral 2 and which is made out of expanded metal having strands 3 and bonds 4. The expanded metal is preferably flattened so that the strands and bonds are compressed substantially into a common plane. Such flattened expanded metal has its opposed faces comparatively smooth and is ideally suited for use in the formation of products of the type here concerned with. The flattening may be accomplished in any appropriate manner, as by pressing or rolling the expanded metal. I find it preferable to pass the expanded metal through a stand of cold rolls and thereby to not only compress the strands and bonds into a common plane but also additionally, cold work the expanded metal to some extent. This provides a product of exceptional strength having highly desirable surface characteristics.

The tray 2 shown in Figure 1 has a rim 5 formed thereabout. Such rim comprises four portions, two of them designated by reference numeral 6 being at the top and bottom edges of the tray as it is shown in Figure 1, and the other two designated by reference numeral 1' being at the side edges of the tray as shown in such figure. Preferably the corners of the sheet of expanded metal are cut out before the rim is formed so that the rim portions I will Vfit between the portions 6 as shown. The rim portions are constituted of the expanded metal itself and are formed by bending the comparatively uneven edge portions of the expanded metal. Such edge portions are generally reversely bent and the edges of the expanded metal are preferably made to lie against and in contact with a face of the expanded metal. Such edges may be, and preferably are, welded to the face of the expanded metal as shown at 8, althoughthe welding may be dispensed with if desired. In the form of structure shown in Figures 1, 2 and 3 the rim 5 projects laterally beyond both faces of the expanded metal. The rim minimizes the eiect of the unevenness of the edges of the expanded metal in addition to facilitating handling of the tray. The uneven edge portions are substantially disposed of or hidden and the tray as a fabricated article has substantially straight and uniform edge portions considering the rim as a whole. There is no danger of cutting or scratching the hands in handling the tray, and the rim propart thereof only.

vides a most effective grip portion. Likewise the formation of the rim results in a desired stiifening ofthe edges of the tray. The tray is light in weight and inexpensive.

In Figures 4 and 5 there is shown a product having a .body portion 9 of flattened expanded metal and a rim Ill at one edge only of the body portion. This product is particularly .adapted for use as a shelf cover, although, as will be apparent, it has numerous other uses. When used as a shelf cover it is adapted to be placed on top of an ordinary woven wire or similar shelf such as is in common use in refrigerators and the like,

also as an abutment member adapted to abut. against the outer edge of the shelf to position the shelf cover relatively to the shelf. Normally the surface of the shelf cover whichis shown as being the top surface in Figures 4 and 5 will be the bottom surface when the cover is in use.

Figure 6 shows a form of structure similar to that of Figures 4 and 5 but in which a core or strengthening rod I I is provided inside the hollow rim. A structure of this character may be desirable for certain uses where exceptional strength is necessary. Preferably the core II is welded within the hollow rim, this being conveniently done by pressure welding. A similar method is used to weld the edge of the expanded metal to ,the face thereof as indicated at 8 in Figures 2 and 3.

It may be desired to form a product having a rim portion having a strengthening core at a This is readily provided for according to the present invention because it is not necessary to form the rim about the core and relatively short core portions may be introduced into desired portions of the hollow rim.

Figure 7 shows another product Inade out of flattened expanded metal and comprising a body portion I2 and an enlarged hollow terminal portion I3. The portion I3 may be substantially the same as the portions 1 of the rim of the tray 2 shown in Figure 1, but in Figure 7 such portion I3 serves as a bearing or hinge portion so that the product shown may function as a gate member, as for a cage or the like. A pivot member or pintle I4 is introduced into the portion I3,- preferably loosely so that the gate member-will pivot thereabout. In such event positioning members I5 may be provided on the member I4 to hold the gate member against longitudinal movement thereon. Alternatively, the gate member may be welded or otherwise permanently secured to the pivot member, the latter being rotatably mounted in `suitable bearings.

In Figures 9, 10 and 11 I have illustrated diagrammatically the formation of a rim portion on a piece of expanded metal, the rim portion shown as being formed in such gures being like the rim portions of Figures 1, 2, 3, 7 vand 8. There are provided a pair of cooperating dies I6 and II. The respective dies have similar opposed recesses IB of generally semi-circular cross section, and the die I'I has another similar recess I9 cooperating with a, projection 20 formed on the die I6. The dies are suitably mounted for guided movement toward and away from each other. A sheet of expanded metal being formed between the dies I6 and I1 is indicated diagrammatically at 2|.

In operation the dies I 6 and I1 are separated and the edge of the sheet 2 I is introduced between the die portions I9 and 20. The dies are then pressed together, deforming 'the edge of the sheet as shown in Figure 9. The dies are then separated and the sheet moved to. the position shown in Figure 10, when the previously deformed edge portion is further deformed between the die portions I9 and 20 as shown. The dies are again separated and the deformed edge portion of the sheet is finally formed between the die portions 8 as shown in Figure 11.

A method of forming a rim portion of the character shown in Figures 4, 5 and 6 is indicated digrammatically in Figures 12, 13 and 14. In such figures reference numeral 22 designates a table having an edge 23. There is also provided a hold-down tool 24 and a forming tool 25 having a generally T-shaped head 26 as shown. A

sheet of expanded metal is indicated diagrammatically at 21.

A sheet 21 is first laid flat on the table with its edge projecting over the edge of the table and is held down by the tool 24. The edge is turned up by a clockwise generally lrotary movement of the tool 25, as, for example, from a position in which the handle of such tool is designated at 28 to the position shown in full lines -in Figure 12.

Substantially the same operation as just described is repeated with the upturned portion of the sheet moved out beyond the edge of the table. This forms a reverse hook at the edge of the sheet as shown in Figure 13. The sheet is then turned through in a horizontal plane until the body of the sheet projects to the left, or beyond the edge of the table, when the upwardly and reversely turned edge portion is held down by the tool 24 and'the body of the sheet turned up by the tool 25 to complete the closed hollow rim as shown in Figure 14.

'I'hus I form-expanded metal products in an extremely simple manner and enable the use of expanded metal in various sheet-like and other products such as trays, tray covers, cage doors, grilles, etc., without resorting to the very undesirable expedient of applying to the expanded metal a separate frame member. I dispose of or hide the uneven edges of expanded metal products by reversely turning such edges against the body ofthe expanded metal and at the same time I provide a product adaptedto be easily handled and which is suitable for many different uses. My product is light in weight yet relatively strong and has a desired degree of rigidity. When the expanded metal is flattened as above described the product is further strengthened and smooth even surfaces are provided.

While I have shown and described certain present preferred embodiments of the invention and certain present preferred methods of forming products in accordance therewith, it is to be distinctly understood that the invention is not so limited but may be otherwise variously embodied within the scope of the following claims.

I claim:v

1. As a new article of manufacture, a sheet of expanded metal comprising'strands and bonds, the sheet having an uneven edge, such edge being reversely turned to form on the sheet a thickened hollow marginal portion constituting a hollow rim of the expanded metal itself and integral with the sheet, said hollow rim minimizing the effect of the unevenness of said`edge and facilitating handling of the sheet.

2. As a new article of manufacture, a sheet of flattened expanded metal comprising strands and bonds compressed substantially into a common plane so that the faces of the sheet are comparatively smooth to the touch, the sheet having, however, an uneven edge, such edge being 4reversely turned to form on the sheet a thickened hollow marginal portion constituting a hollow rim of the expanded metal itself and integral with the sheet, said hollow rim minimizing the eect of the unevenness of said edge and facilitating handling of the sheet.

3. As a new article of manufacture, a product fabricated out of expanded metal comprising strands and bonds, the expanded metal having an uneven edge extending generally parallel to the major axes of the diamonds thereof, such edge being reversely turned to form a thickened marginal portion constituting a rim of the expanded metal itself and integral therewith, said rim minimizing the effect of the unevenness of said edge. `4. As a new article of manufacture, a product fabricated out of flattened expanded metal comprising strands and bonds compressed substantially into a common plane so that the opposed faces of the expanded metal are comparatively smooth to the touch, the expanded metal having, however, an uneven edge, such edge being reversely turned to form a thickened hollow marginal portion constituting a hollow rim of the expanded metal itself and integral therewith, said hollow rim minimizing the effect of the unevenness of said edge. A'

5. As a new article of manufacture, a sheet of expanded metal comprising strands and bonds, the sheet having an uneven edge, such edge being turned to form on the sheet a thickened rim portion of expanded metal projecting laterally beyond both faces of the body of the sheet and facilitating handling of the sheet and minimizing the effect of the unevenness of said edge.

6. As a new article of manufacture, a product fabricated out of expanded metal comprising strands and bonds, the expanded metal having an uneven edge, such edge being reversely .turned and bonded to an adjacent portion of the expanded metal to form a thickened rim portion of expanded metal minimizing the effect of the unevenness of said edge.

'7. As a new article of manufacture, a product fabricated out of flattened expanded metal comprising strands and bonds compressed substantially into a common plane so that the opposed faces of the expanded metal are comparatively smooth to the touch, the expanded metalhaving, however, an uneven edge, such edge being reversely turned and bonded to an adjacent portion of the expanded metal to form a thickened rim portion of expanded met-al minimizing the effect of the unevenness of said edge.

8. A generally rectangular sheet of expanded metal comprising strands and bonds, the sheet having uneven edges, one only of such edges being reversely turned to form on the sheet a thickened rim portion of expanded metalfacilitating handling of the sheet and minimizing the effect of the unevenness of said edge.

9. As a new article of manufacture, a sheet of expanded metal comprising strands and bonds, the sheet having an uneven edge, such edge being reversely turned to form on the sheet a thickened hollow rim portion of expanded metal, and a rod Within said hollow rim portion and welded the product and minimizing `the effect of the thereto, unevenness of said edge.

1o. As a, new article of manufacture, a, product 11- As a new article of manufacture, a product vfabrima'd out of attened expanded metal comfabricated out of expanded metal comprising 5 prising strands and bonds compressed substanlreang dglshugxgggei 1253; 13325 5 tiall into a common lane so that the opposed *facess' of the expandedp metal are comparatively -to form a thickened marginal portion constituting a rim of the expanded'metal itself and inv n i i i i Vizo form a thickened rim portion of expanded al n cross Sect on and mnmlzmg the effect w of the nnevenness of said ed e. metal projecting laterally beyond both faces of E, MACK, 

